Packaging system and method utilizing intelligent conveyor systems

ABSTRACT

A packaging system and method for receiving articles from a first location, such as a product delivery system, transporting the articles to a second location for unloading the articles such that they are placed in a desired orientation and number of columns, rows, and stacks.

RELATED PATENT APPLICATIONS

This application claims priority of U.S. provisional patent applicationNo. 61/705,240, filed Sep. 25, 2012, entitled PACKAGING APPARATUSUTILIZING INTELLIGENT CONVEYOR SYSTEMS, and fully incorporates hereinthe identified provisional patent application by reference.

BACKGROUND OF THE INVENTION

The subject invention relates to packaging systems, and moreparticularly, a packaging system and method utilizing intelligentconveyor systems effective for delivering articles from a first locationto a second location and for placing articles into a desired number ofrows, columns and stacks.

Packaging systems have been developed for transporting articles from amanufacturing operation or storage location to a system for aligning thearticles into a desired configuration for packaging and shipment. Suchsystems often have conveyors with conveyor belts for moving articles toan elevator apparatus that operates to stack the articles into a desiredconfiguration of rows, columns, and stacks then move the stackedarticles for placement into cartons for shipment or to another locationbefore shipment. Such conventional automatic packaging systems howeverare typically very complex, or operate only for moving identicalarticles traveling down a conveyor, or have difficulties in handlingarticles with irregular shapes, or are not easily converted to handledifferent size articles, or are not easily modified or reprogrammed toarrange articles into different packaging configurations.

Further, packaging systems use conventional conveyor systems havingconveyor belts that move articles from one location to a second locationwhereby the articles are removed by hand from the conveyor and placedinto a container or package. Such systems typically depend on theability of one or more individuals to remove the articles and properlyplace them into a container or package. Unfortunately, such systemstypically are unable to adjust the speed of delivery of the articles todifferent unloading stations thereby often resulting in article back-upor articles being displaced or being expelled from the conveyor system.Further, such systems cannot automatically determine if a backup isoccurring and automatically adjust the delivery of articles beingdelivered to that unloading station.

Accordingly, a need exists for a packaging system that can operate toreceive articles from a first location and transport the articles to asecond location for arrangement of the articles into a desired number ofrows, columns, and/or stacks, that can easily handle articles withirregular shapes, and that can be easily converted to handle differentsize articles and/or to arrange the articles into various packagingconfigurations. Further, a need exist for a packaging system that caneasily pack different articles into a single container or package, canbe easily modified to accommodate different product streams, and canautomatically adjust the delivery of articles to one or more unloadingstations.

SUMMARY OF THE INVENTION

The present invention relates to a packaging system for receivingarticles from a product delivery system and to transport the articles toa specific second location, such as an unloading station, to be unloadedand placed into a desired number of columns, rows, and/or stacks.Preferably, the packaging system comprises a first conveyor assemblycomprised of interconnected track sections. Each section has a pluralityof individually controlled electromagnet coils effective for creatingelectromagnetic fields, a plurality of movers or pallets mounted formovement along the conveyor assembly and having magnetic reactionelements positioned thereon. Preferably, the first conveyor assembly isan intelligent conveyor assembly such that each pallet is controlled andmoved independent of each other and electrically coupled to a controlsystem that operates to control the motion of each pallet, and furtherincludes a reaction element, and a control sensor. The reaction elementscooperate with the electromagnetic coils positioned along theinterconnected sections that operate to move the pallets when the coilsare energized. The first conveyor assembly includes an article receivingstation that operates in conjunction with an article delivery system toreceive an article stream of individual articles at a first location anddeliver the articles to a second location, such as an article unloadingstation that receives articles being transported along the firstconveyor assembly by the pallets. The article receiving station includesa loading mechanism that operates to align and place one or moreindividual articles onto pallets. In a preferred embodiment the secondlocation includes a deposit mechanism that operates such that thearticles being transported by the pallets along the first conveyorassembly reach a drop that allows the articles to drop onto a platformfor placement into a package or carton, or onto a second conveyorassembly that move the articles to another second location for furtherprocessing or placement into a package or container.

In a preferred embodiment of the invention, the packaging systemoperates to arrange articles into a desired number of adjacent rows.

In another preferred embodiment of the invention, the packaging systemoperates to arrange articles into a desired configuration of rows andcolumns.

In another preferred embodiment of the invention, the packaging systemcomprises a second conveyor assembly for receiving articles from thefirst conveyor assembly and arranging them into a desired number ofcolumns.

In another preferred embodiment of the invention, the second conveyorassembly operates to arrange articles into a desired number of columns.

In another preferred embodiment of the invention, the first and/orsecond conveyor assembly includes a pivotal pallet effective forchanging the orientation of one or more articles.

In another preferred embodiment of the invention, the second conveyorassembly comprises interconnected track sections, each section has aplurality of individually controlled electromagnet coils effective forcreating electromagnetic fields, a plurality of pallets mounted formovement along the second conveyor assembly and having magnetic reactionelements positioned thereon.

In another preferred embodiment of the invention, each pallet of thesecond conveyor assembly is movable independent of each other andelectrically coupled to a control system that operates to control themotion of each pallet.

In another preferred embodiment of the invention, the pallets include agrasping mechanism for grasping an article as it is transported alongthe conveyor assembly.

In another preferred embodiment of the invention the control systemoperates to control the grasping mechanism such that an article isgrasped at the article receiving station and transported to the secondlocation such that the control system operates to release the articlefrom the grasping mechanism when the article arrives at the secondlocation.

In another preferred embodiment of the invention, each pallet includes ahatch system that operates to allow articles being transported by thepallet to drop into a desired position.

In another preferred embodiment of the invention, the packaging systemincludes a stacking mechanism for stacking articles.

In another preferred embodiment of the invention, the stacking mechanismincludes a stacking platform that operates to receive articles frompallets such that the articles are stacked one upon the other until thedesired number of stacks are obtained.

In another preferred embodiment of the invention, the packaging systemoperates to sense a back-up at a second location, such as an unloadingstation, and automatically adjust the speed of articles being deliveredto that second location.

In another preferred embodiment of the invention, the packaging systemoperates to sense a back-up at a second location, such as an unloadingstation, and automatically stops delivering articles to that secondlocation.

Other advantages of the invention will be apparent from the followingdescription and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To provide a more complete understanding of the present invention andfurther features and advantages thereof, reference is now made to thefollowing description taken in conjunction with the accompanyingdrawings, in which:

FIG. 1 is a schematic illustration of a preferred embodiment of thepackaging system comprising a conveyor assembly for use with an articledelivery system and a second location, such as an article unloadingstation;

FIG. 2 is a schematic illustration of a portion of the interconnectedtrack sections forming a conveyor assembly, each section having aplurality of electromagnet coils and at least one pallet coupled formovement along the track sections for cooperating with reaction elementson each pallet to move the pallets along the track sections;

FIG. 3 is a schematic illustration showing the relationship between theconveyor assembly, the article delivery system, pallets, and the controlsystem of a preferred embodiment of the packaging system;

FIG. 4 is a schematic illustration showing a preferred embodiment of apallet for use with the conveyor assembly of FIG. 1 showing the reactionelements thereon;

FIG. 5 is a schematic illustration of the track assembly of FIG. 1showing a preferred embodiment of an article delivery system and asecond location having a deposit mechanism;

FIG. 6 is a schematic illustration showing of another preferredembodiment of the packaging system of the subject application showing asecond conveyor assembly for receiving articles or stack of articlesfrom a first conveyor assembly and for placing the articles into adesired configuration of rows, columns and or stacks and showing apallet having an article receiving component and an article alignmentcomponent that operate together to ensure that articles being depositedon pallets are maintained in position on the pallets as the palletstravel along the conveyor assembly;

FIG. 7 is a schematic illustration showing the relationship between thefirst conveyor assembly and the second conveyor assembly and having adeposit mechanism for placing articles in a desired configuration;

FIG. 8 is a schematic illustration of another preferred embodiment ofthe packaging system showing a pallet having a gripping mechanism forgripping an article;

FIG. 9 is a schematic illustration of the packaging system of FIG. 6showing a pallet having an article receiving component and an articlealignment component;

FIG. 10 is a schematic illustration of a packaging system of the subjectinvention showing a pallet having a pivotal article receiving componentfor rotating an article of a group of articles into a desiredorientation;

FIG. 11 is a schematic illustration of a packaging system of the subjectinvention showing a portion of a conveyor assembly having one or morepaths diverting therefrom for directing pallets to one or more secondarylocations, such as unloading stations, and for transporting unloadedpallets back to the conveyor assembly;

FIG. 12 is a schematic illustration of a portion the conveyor assemblyof FIG. 12 showing a diverter that operates to change the path of apallet as it travels along the conveyor assembly to allow the pallet tomove to another conveyor assembly or to a second location for unloadingthe pallet;

FIG. 13 is a schematic illustration of another preferred embodiment ofthe packaging apparatus having an article tag system that cooperateswith the control system to ensure that the proper article is placed ontothe proper pallet and for monitoring and maintaining an inventory andpackaging information;

FIG. 14 is a schematic illustration of a preferred embodiment of thecontrol system for controlling the operation of the packaging system ofthe subject invention;

FIG. 15 is a flow diagram showing a preferred method of operation of thepacking system of the subject invention; and

FIG. 16 is a flow diagram showing another preferred method of operationof the packaging system of the subject invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present invention relates to a packaging system for receivingarticles from a first location, such as a product delivery system,transporting the articles to a second location, such as an unloadingstation, for unloading the articles such that they are placed in adesired orientation and number of columns, rows, and stacks. Indescribing the preferred embodiments of the invention illustrated in thedrawings, specific terminology will be resorted to for the sake ofclarity. However, the invention is not intended to be limited to thespecific terms so selected, and it is to be understood that eachspecific term includes all technical equivalents that operate in asimilar manner to accomplish a similar purpose.

Referring to FIG. 1, a portion of a preferred embodiment the packagingsystem 100 of the subject invention is shown comprising a first conveyorassembly 102 having interconnected track sections 104 with an outer wall106. As shown in FIG. 2, mounted to the inner surface 108 of the outerwall 106 are activation elements 110 comprising a plurality ofelectromagnet coils 112 effective for creating electromagnetic fields.

Further, as illustrated in FIGS. 1 and 2, coupled to the first conveyorassembly 102 is a plurality of pallets (or movers) 114 having upperand/or lower mounts 116 and one or more rollers 118 that cooperatetogether for mounting each pallet 114 for movement along the firstconveyor assembly 102. As shown in FIGS. 3 and 4, the first conveyorassembly 102 is an intelligent conveyor system wherein each pallet 114is movable independent of each other and electrically coupled to acontrol system 120 (FIGS. 3 and 14) that operates to control the motionof each pallet 114. Preferably, each pallet 114 includes a reactionelement 122 and a control sensor 124. The reaction element 122preferably comprises one or more magnets 126, such as rare-earthpermanent magnets, which cooperate with the activation elements 110positioned along the first conveyor assembly 102 to produce relativemovement there between when the activation elements 110 are energized.

Referring to FIGS. 3 and 5, in a preferred embodiment of the invention,the first conveyor assembly 102 includes an article receiving station128 that operates in conjunction with an article delivery system 130,such as a conventional conveyor, to receive an article stream 132comprising a plurality of individual articles 134. In a preferredembodiment of the invention, the article delivery system 130 includes aloading mechanism 136, such as a chute, for aligning and placing anindividual article 134 onto a pallet (mover) 114. An article sensor 138is provided and cooperates with the control system 120 (FIGS. 3 and 14)to ensure that a pallet 114 for receiving an article is in properalignment with the loading mechanism 136 for receiving the article 134being feed into the loading mechanism 136 and provides a signal to anoperator and/or to the control system 120.

As shown in FIG. 5, the first conveyor assembly 102 further includes asecond location, such as an article unloading station 140, for receivingarticles 134 being transported to the second location 140 by pallets114. In a preferred embodiment, as shown, the second location 140 is anunloading system such that an article 134 is transported along the firstconveyor assembly 102 by a pallet 114 until it reaches the unloadingstation 140. As shown in this embodiment, the unloading station 140comprises a deposit mechanism 142, such as a drop, that operates todeposit the article(s) 134 onto a platform 143 or directly deposits thearticles into a container or package 145 or onto second conveyorassembly 146, such as a conventional conveyor or an intelligent conveyorsystem as described above, for moving articles 134 to another system orlocation for further processing. It should now be apparent to oneskilled in the art that by controlling the speed S of the pallets 114 orusing two or more deposit mechanisms 142, or using an adjustable depositmechanism (such as one that can pivot) allows the packaging system 100to stack articles into a predetermined number of adjacent stacks 148having a desired proximity to each other. It should also now beunderstood that by controlling the speed S of the pallets 114 travelingalong the first conveyor assembly 102 and the second conveyor assembly146 (or the speed of the pallets 114 b traveling along the secondconveyor assembly 146) allows the packaging system 100 to stack articlesinto a predetermined number of adjacent stacks 148. It should also nowbe apparent to one skilled in the art that by controlling the speed ofthe pallets 114 and the second conveyor assembly 146 (or the speed ofthe pallets 114 b traveling along the second conveyor assembly 146),articles 134 can be placed in a predetermined number of stacks 148having a desired proximity to each other.

In another preferred embodiment, as shown in FIG, 6 and 7, the packagingsystem 100 comprises a first conveyor assembly 102 that operates, suchas shown in FIG. 5 and described above, to place articles into stacks orrows and to transfers such stacks 148 (or individual articles 134, ifstacks are not desired) to a second article receiving station 152 of asecond conveyor assembly 146 and functions to place articles or stacksof articles onto a plurality of secondary pallets 114 b, such as by wayof a chute (not shown). The second conveyor assembly 146 operates totransport articles 134, such as stacks or rows of articles, to asecondary article unloading station 140 b, such as the article unloadingstation 140 described above. It should be understood that the secondaryarticle unloading station 140 b can comprise a drop, slide, or otherapparatus that operates to allow articles 134 (or stacks and/or rows ofarticles) to drop onto a second conveyor assembly 146, such as aconventional conveyor or intelligent conveyor system, for moving thearticles or stacks of articles to another system or another secondlocation for further processing. It should also now be apparent to oneskilled in the art that by controlling the speed of the secondarypallets 114 b and the second conveyor assembly 146 allows the packagingsystem 100 to form stacks having a predetermined number of articles ineach stack. It should also now be apparent to one skilled in the artthat by controlling the speed of the pallets 114 b and the secondconveyor assembly 146, allows articles or stacks of articles to beplaced in a desired number of columns such that the articles are placedin a desired article package configuration 150 of rows, columns andstacks having a desired proximity to each other. In this way, theproduct packaging system of the subject invention allows articles to beautomatically stacked, placed into rows, placed into columns, or placedinto a combination of stacks, rows, and columns.

In another preferred embodiment of the invention, as shown in FIGS. 6and 8, pallets 114 a each include a gripping mechanism 160 such as anelectric-mechanical gripping means that operates to grip an article 134,such as between two gripping heads 162. Preferably, the grippingmechanism 160 is magnetically operated and electrically coupled to thecontrol system 120 (FIG. 3) such that when a pallet 114 a transportingone or more articles 134 is properly positioned in the article receivingstation 128, a sensor 164 transmits a signal to the control system 120that reacts by energizing the gripping mechanism 160 to clasp the one ormore article(s) 134 and carry them to a second location or for placementon a second conveyor assembly 146. The pallets 114 can then move alongthe first conveyor assembly 102 to a second location 140 or to a secondproduct receiving station 128 b of a second conveyor assembly 146 havingpallets 114 b. It should now be apparent to one skilled in the art thatby controlling the speed of the pallets 114 a traveling along the firstconveyor assembly 102, or by controlling the speed of the pallets 114 atraveling along the first conveyor assembly 102 and/or the pallets 114 btraveling along the second conveyor assembly 146, allows the packagingsystem 100 to operate to arrange articles 134 in a desiredconfiguration, such as a desired number of rows, columns and stacks.

After the gripping mechanism 160 has operated to clasp or grab anarticle 134, the pallet 114 a travels along the first conveyor assembly102. It should now be apparent that the pallets 114 a can beindividually controlled, such as by increasing or decreasing the speedthat the pallet is traveling along the first conveyor assembly 102.Further, the pallets 114 a operate to move to a particular locationwhereby the gripping mechanism 160 is released allowing the article 134to be deposited onto a secondary pallet 114 b of the second conveyorassembly 146. Referring to FIG. 6, a preferred embodiment of theinvention is shown whereby pallets 114 a are positioned at predefinedpositions such that when the individual gripping mechanisms 160 releasesthe articles 134 such that the articles are positioned in a desirednumber of rows R (FIG. 15).

As shown in FIGS. 6 and 7, in another preferred embodiment the packagingsystem 100 comprises a first conveyor assembly 102 and a second conveyorassembly 146. The first conveyor assembly 102 includes an articlereceiving station 128 a for receiving individual articles 134 from anarticle stream 132. The first conveyor assembly 102 includes a pluralityof pallets 114 a that each operate to receive at least one article 134at the article receiving station 128 a such as described above. Thepallets 114 a travel along the first conveyor assembly 102 to deliverthe articles to a second location, such as an article unloading station140 a. In a preferred embodiment of the invention, the first conveyorassembly 102 overlaps an article receiving station 128 b of a secondconveyor assembly 146 such that articles 134 being transported bypallets 114 a are deposited on pallets 114 b of the second conveyorassembly 146. It should now be understood that by regulating the speedand placement of pallets 114 a and 114 b, the articles being loaded onpallets 114 b can be placed in a desired number of rows, columns andstacks. In a preferred embodiment of the invention, as shown in FIGS. 6and 9, pallets 114 b further comprise an article receiving component 166and an article alignment component 168 that operate together to ensurethat articles 134 being deposited on pallets 114 b are maintained inposition on the pallets 114 b as the pallets travel along the secondconveyor assembly 146. It should be understood that as described abovethe article receiving component 166 and the article alignment component168 each include a reaction element and a control sensor and thereaction element cooperate with the activation elements positioned alongthe track assembly to produce relative movement there between when theactivation elements are energized (such as described above).Accordingly, the article receiving component 166 and the articlealignment component 168 can each move independent from each other.

Referring to FIG. 10, another preferred embodiment of the packagingsystem 100 of the subject invention is shown in which the pallets 114traveling around the first conveyor assembly 102 includes an articlereceiving component 166 that is pivotally coupled, such as by anelectrically driven rotating plate 115, to upper and lower mounts 116such that article(s) being transported by a pallet 114 and be rotatedinto a desired orientation.

Referring to FIGS. 11 and 12, another preferred embodiment of thepackaging system of the subject invention is shown whereby pallets 114traveling along a first conveyor assembly 102 operate to move one ormore articles 134 to one or more second locations 140, such as one ormore article unloading stations. As shown, in a preferred embodiment thefirst conveyor assembly 102 includes a switching apparatus 170, such asan electromagnetic switch, that can be operated by the control system120 to move a portion 172 of the first conveyor assembly 102 (orredirect the such that upper and lower mounts 116) such that the pallets114 traveling along the first conveyor assembly 102 are diverted to asecondary rail 174 that directs the pallets 114 to a second location,such as an article unloading station 140. Once the article(s) areunloaded from the pallet(s) 114, the unloaded pallets 114 are thendirected to move along the secondary rail 174 until they merge with andcontinue traveling along the first conveyor assembly 102. In a preferredembodiment of the invention, the packaging system 100 includes anarticle sensor 176 that operates to sense if the articles 134 have beenunloaded from the pallet 114 and transmits a signal 178 to the controlsystem 120 when the pallet has been unloaded. Preferably, the pallets114 remain at the unloading station 140 until the control system 120receives the signal 178 that the pallets have been unloaded. In apreferred embodiment of the invention, the control system 120 canoperate such that no additional pallets are directed to the particularunloading station 140 until the pallets at that unloading station havebeen unloaded thereby reducing or preventing pallets from deliveringarticles to the unloading system at a speed faster than the articles canbe unloaded. Further, in another preferred embodiment of the invention,the control system can operate such that pallets are not directed to aparticular second location or unloading station, such as in the event anoperator or an unloading apparatus or device is not functioning at theunloading station.

As illustrated in FIG. 13, another preferred embodiment of the packagingapparatus 100 includes an article tag system 180 that cooperates withthe control system 120 to ensure that the proper article 134 is placedonto the proper pallet 114. In a preferred embodiment, the tag system180 includes a tag 182 attached to each article 134 a plurality of tagreaders 184 such that each pallet 114, 114 b includes a tag reader 184mounted thereon. In a preferred embodiment, the tag 182 is in the formof a bar code and the tag reader 184 is a bar code reader. In anotherpreferred embodiment, the tag 182 is in the form of a radio frequencyidentification devices (RFID) comprising a RFID tag 182 and the tagreader 184 which is in the form of a RFID reader. Each tag 182 providesa unique code for the particular article 134. For example, each article134 of a particular type can have the same unique code. In anotherpreferred embodiment, each article 134 can have its own unique code. Itshould be understood that the unique code is transmitted to the controlsystem 120 which is then used to monitor the movement of the article 134as it travels from a storage location, along the track assembly, to adesignated location. It should also be understood that using RFID tagsand by connecting the tag reader in the form of a RFID reader toindividual movers, allows for the tag to be in the form of a relativelyinexpensive passive RFID tag. It should also be understood that the useof an RFID tag and reader eliminates the need for the tag to be placedin a specific location and facing in a direction to be read by theoptical reader necessary for bar code scanning systems or other opticaltag and scanner systems.

Referring to FIG. 14, the control system 120 is shown comprising aprocessor 200, such as a computer and other devices, having a memory 202and suitable input device 204, like a keypad, touch screen, or any othersuitable input device that can accept information or instructions froman operator (including operating instructions directing movement orcontrolling the direction or path of a pallet); one or more suitableoutput devices 206, such as a computer display, printer, image-formingor display device, and the like. It should be understood that the memory202 can include any conventional data storage device such as any of theusual devices used for the storage of data, such as computer harddrives, floppy discs, binary codes, optical bits, mechanical scribes,magnetic tapes, compact discs, digital audio tapes, analog tapes, vinyldiscs, and any device or devices capable of storing data. It should alsobe understood that the control system 120 can include any combination ofthe above components, or any number of different components,peripherals, and other devices. Preferably, the control system 120operates under the control of an operating system, such as the WINDOWSoperating system developed by Microsoft Corporation or the MACINTOSHoperating system developed by Apple Computer Corporation. It should beunderstood, however, that other operating systems could be utilized toimplement the system software 208.

Referring to FIG. 15, a preferred embodiment of the invention is shownwhereby an operator enters into the control system using the inputdevice, information identifying the article, as well as information suchas the number of articles, and the desired packaging configuration(number of rows, columns, and stacks, including the number of articlesin each stack) (Step 300). The control system then operates to directone or more pallets (movers) along a first conveyor assembly such thateach pallet aligns with one or more article delivery systems such thatone or more articles are loaded onto one or more pallets (Step 302). Ina preferred embodiment, the two or more articles can be loaded onto anindividual pallet to form a stack. The control system then operates toindividually control each pallet as it travels along the first conveyorsystem to the pallet's designated second location (Step 304). At thedesignated second location, the control system operates such that eachpallet is unloaded by a deposit mechanism (step 306) that functions todeposit the articles from a pallet directly onto a platform or into acontainer or package (Step 308), or deposits the articles onto a palletstraveling along a second conveyor assembly (Step 310). In a preferredembodiment of the invention, the control system further operates toadjust the speed of each pallet traveling along the first and/or secondconveyor assemblies to adjust the number and/or proximate adjacentplacement of the stacks of articles (Step 312). In another preferredembodiment of the invention, the deposit mechanism operates to create adesired number of rows and columns of articles (Step 314). In anotherpreferred embodiment of the invention, the control system also operatesto pivot the pallets such that the articles are unloaded and depositedonto a platform or into a container or onto the second conveyor assemblyin a desired orientation (Step 316). The pallets traveling along thesecond conveyor assembly are directed to an unloading station where theyare unloaded as described in Steps 306 and 308 above.

In another preferred embodiment, as shown in FIG. 16, the method ofoperation includes inputting information into the control system usingthe input device, information identifying the article, as well asinformation such as the number of articles, and the desired packagingconfiguration (number of rows, columns, and stacks, including the numberof articles in each stack) (Step 400). Using a conveyor assembly,wherein the conveyor assembly is an intelligent conveyor system, anddirecting the individual pallets (movers) into position to receive astream of individual articles (Step 402) and placing one or morearticles on the individual pallets (Step 404). Each pallet is thendirected to one or more unloading stations for unloading articles fromthe individual pallets (Step 406). The control system further operatessuch that the individual pallets remain at the at least one articleunloading station until the articles are unloaded from the pallet (Step408). It should be understood that the control system operates tocontrol the speed of the pallets traveling along the conveyor assemblyto as well as selecting the unloading station that will receive apallet, such as diverting a pallet from one unloading station to anotherunloading station, to ensure that a back-up of pallets (articles beingdelivered) does not occur. Further, the control system will operate tomaintain a pallet (mover) at a unloading station until the pallet hasbeen unloaded (Step 410).

It should now be apparent to one skilled in the art that the packagingsystem of the subject invention operates to receive and transportarticles from a first location, such as a storage location, andtransport the articles to a second location such that the articles areunloaded and placed into a desired number of rows, columns, and/orstacks, can easily handle articles with irregular shapes, and can beeasily converted to handle different size articles and/or to arrange thearticles into various packaging configurations. Further, it should nowbe apparent that the packaging system of the subject invention caneasily handle articles with irregular shapes, can be easily converted tohandle different size articles and/or to arrange the articles intovarious packaging configurations. Further, the packaging system of thesubject invention can easily pack different articles into a singlecontainer or package, can be easily modified to accommodate differentproduct streams, and can automatically adjust the delivery of articlesto one or more unloading stations.

While the methods and components described herein constitute preferredembodiments of the invention, it is to be understood that the inventionis not limited to the precise method and components, and that changesmay be made therein without departing from the scope of the inventionwhich is defined in the appended claims.

1.-20. (canceled)
 21. A packaging system comprising: a first conveyorassembly having a plurality of first individual supports movable alongthe first conveyor assembly independently of one another; a secondconveyor assembly having a plurality of second individual supportsmovable along the second conveyor assembly independently of one another;an article transfer system configured to unload articles from the firstindividual supports of the first conveyor assembly and to place thearticles on second individual supports of the second conveyor assembly;and a control system configured to control motion of the first andsecond individual supports traveling along the first and second conveyorassemblies.
 22. The packaging system of claim 21, comprising an articlereceiving station configured to receive a stream of individual articlesand to place one or more articles on the individual supports of thefirst conveyor assembly.
 23. The packaging system of claim 21, whereinthe first conveyor assembly comprises a plurality of interconnectedfirst track sections.
 24. The packaging system of claim 23, wherein eachof the first individual supports comprises a mover displaceable alongthe first track sections by control of electromagnetic fields producedby coils of the first track sections.
 25. The packaging system of claim21, wherein the second conveyor assembly comprises a plurality ofinterconnected second track sections.
 26. The packaging system of claim25, wherein each of the first individual supports comprises a moverdisplaceable along the second track sections by control ofelectromagnetic fields produced by coils of the second track sections.27. The packaging system of claim 21, comprising a an article sensorconfigured to provide a signal to an operator and/or to the controlsystem if the article is not placed properly on an individual support.28. The packaging system of claim 21, wherein the control systemoperates to regulate speeds of the first and second individual supports.29. The packaging system of claim 21, comprising a gripping mechanismconfigured to grasp one or more articles and to place the one or morearticles onto the individual supports.
 30. The packaging system of claim21, wherein the individual supports of at least one of the first andsecond conveyor assemblies are pivotally coupled to mounts to rotatearticles being transported by the supports into desired orientations.30. The packaging system of claim 21, wherein at least one of the firstand second conveyor assemblies includes a switching apparatus configuredto divert one or more individual supports.
 31. The packaging system ofclaim 30, wherein the switching apparatus diverts the one or moreindividual supports to a desired article unloading station.
 32. Apackaging system comprising: a first conveyor assembly having aplurality of first individual supports movable along the first conveyorassembly independently of one another; a second conveyor assembly; anarticle transfer system configured to unload articles from the firstindividual supports of the first conveyor assembly and to place thearticles on the second conveyor assembly; a switching apparatusconfigured to divert one or more individual supports to a desiredlocation; and a control system configured to control motion of the firstindividual supports traveling along the first conveyor assembly andswitching of the switching apparatus.
 33. The packaging system of claim32, wherein the second assembly comprises a plurality of secondindividual supports movable along the second conveyor assemblyindependently of one another, and wherein the control system controlsmotion of the second individual supports.
 34. The packaging system ofclaim 32, wherein the control system is configured to regulate speeds ofthe first individual supports traveling along the first conveyorassembly.
 35. The packaging system of claim 32, wherein the firstconveyor assembly includes a gripping mechanism configured to grasp oneor more articles and place the one or more articles onto one of theindividual supports.
 36. The packaging system of claim 32, wherein theindividual supports of the first conveyor assembly are pivotally coupledto mounts to rotate the articles being transported by the supports intoa desired orientation.
 37. A packaging system comprising: a firstconveyor assembly having a plurality of first individual supportsmovable along the first conveyor assembly independently of one another;a second conveyor assembly having a plurality of second individualsupports movable along the second conveyor assembly independently of oneanother; means for transferring articles from the first individualsupports of the first conveyor assembly second individual supports ofthe second conveyor assembly; a control system configured to controlmotion of the first and second individual supports traveling along thefirst and second conveyor assemblies; and means for rotating individualsupports of at least one of the first and second conveyor assembliesinto a desired orientation.
 38. The method of claim 37, wherein at leastone of the first and second conveyor assemblies includes a switchingapparatus configured to divert one or more individual supports.
 39. Themethod of claim 37, wherein the control system is configured to regulatespeeds of the individual supports traveling along at least one of thefirst and second conveyor assemblies.
 40. The packaging system of claim37, comprising a gripping mechanism configured to grasp one or morearticles and place the one or more articles onto one of the individualsupports.